Cafe Express Owners Manual - Club Car

CAFE EXPRESS Vehicle Owner’s Manual Gasoline [Refer to back cover for applicable build code range]

NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual. If the vehicle build code is different from that shown on the back cover of this manual, please contact your nearest dealer or go to www.clubcar.com to retrieve the proper owner’s manual for the vehicle. See also Model Identification in this manual. Warranty information appears at the end of this manual. No other warranties, express or implied, are contained herein. Your authorized representative checked the vehicle before it was delivered to you and will provide you a copy of the completed vehicle warranty registration form. Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of this manual may be photocopied, reproduced, or translated to another language without the written consent of Club Car, LLC. The information contained in this document is subject to change without notice. Club Car reserves the right to make design changes to vehicles without obligation to make these changes on units previously sold. These utility vehicles are four-wheel, general-purpose vehicles intended to transport people and cargo on improved or groomed surfaces. These vehicles do not conform to U.S. Federal Motor Vehicle Safety Standards (FMVSS) for automobiles or to FMVSS 500 for low-speed vehicles, and are not equipped for operation on public streets, roads, or highways. If in English, this manual is the Original Instructions provided by the manufacturer. If in any language other than English, this manual is a translation of the Original Instructions.

P.O. Box 204658 Augusta, Georgia 30917–4658 USA Telephone 706–863–3000 Service Parts Fax 706–855–7413 www.clubcar.com

Copyright © 2013 Club Car, LLC Club Car, Tranquility, and ArmorFlex are registered trademarks of Club Car, LLC This manual effective January 1, 2014

CAFE EXPRESS Vehicle Owner’s Manual

Page 1

FOREWORD Thank you for choosing Club Car, the name most widely recognized as the industry leader in vehicle efficiency and long-lasting value. You have chosen the finest utility vehicle on the market. Please protect your investment and ensure that your Club Car vehicle(s) provides years of reliable, superior performance by reading and following the maintenance instructions in this manual. Your comfort and safety are important to us, so we urge you to read and follow the step-by-step operating instructions and safety procedures in this manual. These instructions must be followed in order to avoid the risk of serious personal injury. If you rent or loan your vehicle to others, we recommend that you ask them to read this manual before they operate the vehicle. Club Car products are backed by a customer support system designed to offer you fast, courteous service. In the event your Club Car vehicle needs repairs or service, please contact your local authorized Club Car dealer or distributor, who will be able to provide technical advice, perform warranty work, and sell parts and service manuals. For the name and address of the authorized Club Car dealer or distributor nearest you, logon to our web site at ClubCar.com or call 1-800-ClubCar (258-2227). If you would prefer to write to us, direct your letter to: Club Car, Attention: Marketing Services, P.O. Box 204658, Augusta, Georgia 30917-4658 USA. We hope you will consider this owner’s manual a permanent part of your Club Car vehicle. If you sell the vehicle, please include the manual so that the next owner will have the important operating, safety, and maintenance information it contains. MAINTENANCE ITEMS Battery Terminal Protector Spray

Engine Air Filter (404 cc)

CC PN 1014305

CC PN 102558201

Chassis Lube

Spark Plug O.H.C. (404 cc)

EP NLGI Grade 2 (commercially available)

CC PN 105017801

Dry Moly Lube CC PN 1012151

Page 2


TABLE OF CONTENTS Safety Decal Identification ..................................................................................................................................... 4 Practice Safety ..................................................................................................................................................... 7 Proposition 65 – State of California ........................................................................................................................ 8 Safety Details ....................................................................................................................................................... 8 General Warnings................................................................................................................................................. 8 General Information .............................................................................................................................................11 Model Identification............................................................................................................................................. 12 Controls and Indicators ....................................................................................................................................... 12 Pre-Operation and Daily Safety Checklist ............................................................................................................. 18 Vehicle Operation ............................................................................................................................................... 19 Driving Instructions ............................................................................................................................................. 21 Loading and Unloading ....................................................................................................................................... 23 Vehicle Load Capacities ...................................................................................................................................... 23 Refreshment Center ........................................................................................................................................... 24 Towing with the Vehicle ....................................................................................................................................... 25 Transporting on a Trailer ..................................................................................................................................... 25 Storage.............................................................................................................................................................. 25 Maintenance ...................................................................................................................................................... 28 Periodic Service Schedule................................................................................................................................... 28 Periodic Lubrication Schedule ............................................................................................................................. 30 Battery ............................................................................................................................................................... 31 Engine Oil – Gasoline Vehicle.............................................................................................................................. 32 Fueling Instructions – Gasoline Vehicle ................................................................................................................ 35 Cleaning the Vehicle ........................................................................................................................................... 36 Accessories........................................................................................................................................................ 37 Subsequent Owner Registration .......................................................................................................................... 38 Vehicle Specifications ......................................................................................................................................... 39 Warranties.......................................................................................................................................................... 41 EC Declaration of Conformity .............................................................................................................................. 48


Page 3

Safety Decal Identification

SAFETY DECAL IDENTIFICATION The following pages contain safety decal information. For detailed information on specific features, read the appropriate section in this manual.

CAFE EXPRESS VEHICLE

4 2

5

1

6

3

2904 1

101609401

2

101825101

3

102278901

Page 4

Decal, Crush Area Warning (behind seat, near

4

104026801

Decal, Occupant Warning

Decal, On/Off Key Switch (above key switch)

5

105046101

Decal, Operating Instructions

Decal, Vehicle Load

6

105185901

Decal, Rollover Warning

cargo bed)



CAFE EXPRESS VEHICLE, CONTINUED

5

6 2

4

3

1

2905 1

101915201

2

101960501

3

102459301

Decal, Frame Ground/Governor Warning (on vehicle frame near battery) Decal, Rotating Parts/Hot Manifold Warning (on starter/generator) Decal, Bed Latch Warning

Decal, Maintenance/Operate Warning (on

4

103205501

5

105082301

Decal, Gasoline Fuel Warning (on fuel tank)

6

105084701

Decal, Gasoline Fuel Warning (at fuel fill)

Maintenance/Operate switch plate, under seat)


Page 5


CAFE EXPRESS UNIT

6 1 3

10

11

5 2

4

9

7

8

2906 Decal, Food Safety Warning (on each side of

1

1011962

2

101553901

3

102160601

4

102175901

5

105185902

6

SVP203101

Page 6

7

Dry Snack Compartments

Decal, Bed Loading Warning

8

Cold Storage Compartment

Decal, Canopy Pin Caution

9

Consumable Ice Compartment

10

Carafe Compartment

11

Trash Compartment

refreshment unit)

Decal, Consumable Ice (on each side of refreshment unit) Decal, Beverage Unit Rollover Warning (on each side of refreshment unit) Decal, Proper Use Notice (on each side of refreshment unit)


Practice Safety

PRACTICE SAFETY

399

Figure 1

Practice Safety

Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. Your safety and satisfaction are of the utmost importance to us. That is why before operating the vehicle, we urge you to review the information in this manual. Understand and become familiar with the DANGER, WARNING, and CAUTION statements and procedures it contains, along with the safety decals that are affixed to your vehicle. Take time to understand the language of safety. It is a language that can save your life.

SAFETY VIDEO AND ONLINE TRAINING PROGRAM A vehicle safety video is provided with the vehicle. Have all operators view the safety video, and understand the safety warnings it illustrates, before operating the vehicle. If a safety video was not provided with your Cafe Express vehicle, you may obtain one through your service parts representative. Online training for this product is available on the Club Car website at www.clubcar.com/resources/pages/eLearning.aspx. Prior to operating the vehicle, operators should complete the training. Our e-learning program allows our customers to document employee training and to monitor each employee’s achievement record. The program will record an employee’s completion status, and establishes a record of training for supervisors and managers based on information provided by the employee at login.


Page 7

Proposition 65 – State of California

PROPOSITION 65 – STATE OF CALIFORNIA WARNING • This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm.

SAFETY DETAILS WARNING • This manual should be read completely before attempting to drive or service the vehicle. The safety video provided with the Cafe Express vehicle and the online training should also be viewed by all operators of the vehicle. Failure to heed the warnings or follow the instructions in this manual and the training material can result in serious personal injury or death. It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER, WARNING, or CAUTION. For your protection, we recommend that you take special notice of these safety precautions. Safety precautions are essential and must be followed. If any of the operation or safety decals on the vehicle become damaged, have been removed, or cannot be easily read, they should be replaced immediately to avoid possible property damage, personal injury, or death. Contact your distributor/dealer.

DANGER • A DANGER indicates an immediate hazard that will result in severe personal injury or death.

WARNING • A WARNING indicates an immediate hazard that can result in severe personal injury or death.

CAUTION • A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that can result in minor personal injury.

CAUTION • A CAUTION without the safety alert symbol indicates a potentially hazardous situation that can result in property damage.

GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated, repaired, or serviced. See Safety Decal Identification on page 4. Other specific safety statements appear throughout this manual and on the vehicle.

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General Warnings

DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. • Gasoline – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. • Do not operate engine in an enclosed area without proper ventilation. The engine produces carbon monoxide, which is an odorless, deadly poison. • The vehicle will not provide protection from lightning, flying objects, or other storm-related hazards. If caught in a storm while driving a Club Car vehicle, exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location.

WARNING • Follow the procedures exactly as stated in this manual, and heed all DANGER, WARNING, and CAUTION statements in this manual as well as those on the vehicle and battery charger. • Do not leave children unattended in vehicle at any time. • Prior to leaving the vehicle unattended or servicing the vehicle, set the park brake, place the Forward/Reverse handle or switch in the NEUTRAL position, turn the key switch to the OFF position, and remove the key. Chock the wheels when servicing the vehicle. • Improper use of the vehicle or failure to properly maintain it can result in decreased vehicle performance, serious personal injury, or death. • Any modification or change to the vehicle that affects the electrical system, stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, can result in serious personal injury or death. • Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read. • For vehicles with cargo beds, remove all cargo (including accessories) before raising the bed or servicing the vehicle. If the vehicle is equipped with a prop rod, ensure that it is securely engaged while bed is raised. Do not close bed until all persons are clear of cargo bed area. Keep hands clear of all crush areas. Do not drop cargo bed; lower gently and keep entire body clear. Failure to heed this warning can result in serious personal injury or death. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation. • To avoid unintentionally starting the vehicle, disconnect the battery and spark plug wire. See Disconnecting the Battery on page 10. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring. Do not allow a positive wire to touch the vehicle frame, engine, or any other metal component. • Wear safety glasses or approved eye protection when servicing the vehicle. Wear a full face shield and rubber gloves when working on or near batteries. • Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the vehicle. • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring.

DISABLING THE VEHICLE 1.

Engage park brake to lock wheels.

2.

Turn the key switch OFF and remove the key.


Page 9

General Warnings 3.

Place the Forward/Reverse control in the NEUTRAL position.

4.

In addition, chock the wheels if servicing or repairing the vehicle.

DISCONNECTING THE BATTERY 1. 2.

Disable the vehicle. See Disabling the Vehicle on page 9. Disconnect the battery cables, negative (–) cable first, as shown (Figure 2).

3.

Disconnect the spark plug wire from the spark plug.

CONNECTING THE BATTERY 1.

Connect the battery cables, positive (+) cable first.

2. 3.

Tighten battery terminals to 80 in·lb (9 N·m). Coat terminals with Battery Terminal Protector Spray to minimize corrosion.

4.

Connect the spark plug wire to the spark plug.

2 1

1

Figure 2 Battery Cable Removal

RECYCLING LEAD-ACID BATTERIES

WARNING • Lead-acid batteries contain lead (Pb), other metals, acids and other compounds. If improperly handled, they can contaminate both water and soil, causing environmental damage and personal injury. Lead-acid batteries are identified by the symbol shown below and should be properly recycled (Figure 3). They cannot be disposed as municipal waste and must be collected separately. Responsibility for environmental protection must be shared, not only by the manufacturers of the batteries, but by people who use the batteries as well. Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries.

Page 10


General Information

1403

Figure 3 Dispose of Lead-acid Batteries Properly

INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using, repairing, or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries.

2

1

4

3

6

5

1. Shield eyes.

3. No smoking, no open flames, no sparks.

5. Battery acid hazard.

2. Read and follow operating instructions.

4. Keep away from children.

6. Explosive gas hazard.

Refer to General Warnings for more information.

1642

Figure 4

International Safety Symbols on Batteries

GENERAL INFORMATION This manual features the Cafe Express gasoline vehicle, which is equipped with a Subaru engine and accompanying powertrain and a pedal-start configuration. Throughout this manual, important features are highlighted. We urge the owner/operator to read and understand this manual.


Page 11

Model Identification

MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted below the center dash panel (Example: CC5819-123456) (Figure 5). The two letters (1) at the beginning of the serial number indicate the vehicle model. The following four digits (2) indicate the model year and production week during which the vehicle was built. The six digits (3) following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year. See following NOTE. NOTE: Have the vehicle serial number available when ordering parts or making inquiries. Build Code: The build code (4) is a five-digit number that appears on the vehicle serial number decal. The build code exists to enable the user to identify the correct owner’s manual for a vehicle. This owner’s manual is valid for the build code range indicated on the back cover of this owner’s manual.

1

4

2

3

SERIAL NUMBER

CC5819-123456

BC54679 ASSEMBLED IN USA

2843

Figure 5 Serial Number Decal

CONTROLS AND INDICATORS See General Warnings on page 8.

WARNING • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • Do not tamper with the governor. Doing so will void the warranty, as well as damage the engine and other components, and can result in property damage, personal injury, or death due to unsafe speeds.

KEY SWITCH The key switch (1) is mounted on the dash to the right of the steering column (Figure 6). Each vehicle is equipped with a two-position key switch. Gasoline vehicles equipped with a two-position key switch are referred to as “pedal-start”.

Page 12


Controls and Indicators

WARNING • Moving parts! Keep clear of the engine compartment while the engine is running. NOTE: When the key is turned to the OFF position, the main vehicle systems are disabled. The key switch may be used as an emergency shut-off. The key can be removed only when the key switch is in the OFF position.

FORWARD/REVERSE CONTROL Gasoline Vehicles The Forward/Reverse handle (2) is located at the bottom center of the instrument panel (Figure 6). The handle has three distinct positions: F (FORWARD), N (NEUTRAL), and R (REVERSE). Push the handle up to operate the vehicle in the forward direction, or pull the handle down to operate the vehicle in reverse. • The engine will not run when the handle is in the NEUTRAL position. Club Car vehicles operate at reduced speed in reverse. The reverse buzzer will sound as a warning when the Forward/Reverse handle is in the REVERSE position.

4

5

3

6

1 2

2821

Figure 6 Instrument Panel

HEADLIGHT CONTROL Vehicles with Headlights The headlight switch (3) is located on the right side of the instrument panel (Figure 6). Press the side of the switch with the headlight symbol to turn the headlights on and press the other side to turn the headlights off. NOTE: Using the headlights for extended periods of time without the engine running or with the engine idling will discharge the battery.

LOW OIL WARNING LIGHT The gasoline vehicle is equipped with a low oil warning light (4), located at the top of the instrument panel (Figure 6). If the warning light comes on, oil should be checked and added to the engine as necessary before continuing to use the vehicle. See following CAUTION. The vehicle should never be driven when the low oil warning light remains on. If the CAFE EXPRESS Vehicle Owner’s Manual

Page 13

Controls and Indicators warning light goes on and off, the vehicle may be driven, but oil should be added at the first opportunity. The light will flash repeatedly to indicate a possible problem with the electronic fuel injection (EFI) system. If the oil level is correct and the warning light stays on, have a trained technician check the vehicle.

CAUTION • Failure to add oil immediately when the low oil warning light stays on can result in permanent engine damage.

FUEL GAUGE/HOUR METER (OPTIONAL) If so equipped, the fuel gauge/hourmeter (5) is located on the instrument panel (Figure 6). The fuel gauge allows the operator to monitor the fuel level in the vehicle. The hour meter should be used by the trained technician to track vehicle usage and determine when periodic service procedures are required. See Periodic Service Schedule on page 28.

ELECTRIC BED LIFT (OPTIONAL) The electric bed lift switch (6) is located on the upper left side of the instrument panel (Figure 6). To lift the bed, press the side of the switch with the up arrow, and press the other side of the switch to lower the bed. The bed lift will make a loud clicking sound to signal the bed is in the rest position.

WARNING • Keep clear of moving parts when bed is in the raised position and the engine is running. • Keep hands and fingers clear of crush area between the bed and the seat back support.

CAUTION • Canopy pins must be removed before lifting the bed.

12-VOLT POWER POINT A 12-volt power point is located in the driver’s side dash pocket and is rated at 6.5 amps (Figure 7). When the key switch is in the ON position, the power point provides power to accessories plugged into it. The electrical circuit to the power point also powers all additional electrical accessories on the vehicle and is protected by a 10-amp fuse. Exceeding a 10-amp total draw on the circuit will result in a blown fuse. NOTE: The power point is not for continuous use. Extended use can cause the vehicle battery to become heavily discharged. Do not use the power point for long periods of time when the engine is not running.

Page 14



2848

Figure 7 12-Volt Power Point

ACCELERATOR PEDAL The accelerator pedal is the pedal on the right, with the word GO molded into it (Figure 8). When the key switch is in the ON position, and the Forward/Reverse handle or switch is in either the FORWARD or REVERSE position, pressing the accelerator pedal will automatically release the park brake and start the vehicle moving in the direction selected (forward or reverse). When the accelerator is released, power will be cut off and the motor or engine will stop running. See following WARNING and CAUTION.

WARNING • Moving parts! Keep clear of the engine compartment while the engine is running.

77

Figure 8 Accelerator and Brake Pedals


Page 15


BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it (Figure 8). To slow or stop the vehicle, press the brake pedal with your right foot (Figure 9).

PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal. It has the word PARK molded into it and the words PARK BRAKE marked on top of it (Figure 8). To set the park brake, press the brake pedal firmly and tilt the park brake portion of the pedal forward with your foot (Figure 10). See following WARNING.

WARNING • The park brake will release automatically when either the accelerator or brake pedal is pressed. The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling.

79

78

Figure 9 Brake Pedal

NEUTRAL LOCKOUT SWITCH

81

Figure 11 Neutral Lockout Switch

Page 16


Figure 10 Park Brake

Controls and Indicators For the convenience of the trained technician, there is a neutral lockout switch located on the seat support panel under the seat (Figure 11). The neutral lockout switch has two positions, MAINTENANCE and OPERATE, which are clearly marked. When the switch is in the MAINTENANCE position, it will allow the technician to run the engine in the NEUTRAL position to perform certain maintenance and/or repair functions. With the switch in this position, the vehicle will not operate if the Forward/Reverse handle is placed in either the FORWARD or REVERSE position.

WARNING • With the switch in the MAINTENANCE position and the engine running, the vehicle can move suddenly if the Forward/Reverse handle is shifted or accidentally bumped. To prevent this, chock the front and rear wheels and firmly set the park brake before servicing or leaving the vehicle. NOTE: Be sure to return the switch to the OPERATE position after servicing the vehicle, or it will not run with the Forward/Reverse handle in either the FORWARD or REVERSE position.

BED LATCH

CAUTION • The canopy frame must be disconnected from the top of the windshield frame before raising the bed. Failure to do so will result in vehicle or canopy damage. The vehicle is equipped with a bed latch on the driver side of the vehicle (Figure 12). To lift the bed, remove canopy pins, then pull the latch handle toward the rear of the vehicle and lift the bed. To close the bed, lower it gently until the bed latch engages. DO NOT drop the bed. Connect the canopy frame to the top of the windshield frame by installing the canopy pins.

WARNING • Keep hands and fingers clear of crush area between the bed and the seat back support. • Unload the refreshment center before lifting the bed. NOTE: The vehicle is equipped with an automatically engaging prop rod (Figure 13), unless equipped with the electric bed lift option.

2828

2827

Figure 12 Bed Latch

Figure 13 Prop Rod


Page 17

Pre-Operation and Daily Safety Checklist

PROP ROD

CAUTION • The canopy frame must be disconnected from the top of the windshield frame before raising the bed. Failure to do so will result in vehicle or canopy damage. The vehicle is equipped with an automatically engaging prop rod and prop rod track on the driver side of the rear body (Figure 13). Remove canopy pins before lifting bed. When pulling the bed latch handle and lifting the bed, the prop rod will come to rest in one of the notches in the prop rod track.

DANGER • Use caution when working under bed. Be sure prop rod is secure. Otherwise the bed will fall, resulting in severe personal injury or death.

WARNING • Do not disengage prop rod until all persons are clear of refreshment center bed area. • Do not drop tilt bed; lower gently and keep entire body clear. Failure to follow these instructions could result in severe injury. • Keep hands clear of crush area between bed and seat back support. To lower the bed, lift the bed so that the prop rod is no longer supported in one of the track notches. Push the prop rod toward the front of the vehicle to free it from the track notch and gently lower the bed. DO NOT drop the bed. Connect the canopy frame to the top of the windshield frame by installing the canopy pins.

PRE-OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery. Use the following checklist as a guide to inspect the vehicle. This checklist should be used daily to ensure that the vehicle is in proper working condition and in conjunction with the Performance Inspection on page 19 and the Periodic Service Schedule on page 28. Any problems should be corrected by a Club Car distributor/dealer or a trained technician. Do not operate the vehicle until the upper cabinet, canopy, and windshield have been installed. • Safety Video: Have all operators view the safety video that was provided with the vehicle and understand the safety warnings it illustrates before operating the vehicle. • General: All the parts should be in place and properly installed. Be sure that all nuts, bolts, and screws are tight. On gasoline vehicles, check all hose clamps for tight fit as well as the starter belt for tightness. • Windshield: Ensure that the windshield is installed before driving the vehicle. • Safety and information decals: Check to ensure that all safety and information decals are in place. See Safety Decal Identification on page 4. • Tires: Check for proper tire pressure upon delivery and on a daily basis when the vehicle is in service. See Vehicle Specifications on page 39. • Loading: Before driving the vehicle, ensure that the load weight is evenly distributed in the Cafe Express refreshment center. • Battery: Check electrolyte to ensure that it is at its proper level (Figure 17). Check battery posts. Wires should be tight and free of corrosion. On electric vehicles, charge batteries fully before first use of vehicle. Page 18


Vehicle Operation • Engine: Check for proper engine oil level. See Engine Oil – Gasoline Vehicle on page 32. Inspect air intake for blockage. • Fuel: Check fuel level. See Fueling Instructions – Gasoline Vehicle on page 35. Check fuel tank, fuel injector, lines, cap, and pump for fuel leakage on a daily basis. • Performance Inspection: Inspect as instructed. See Performance Inspection on page 19.

WARNING • Be sure the plastic has been removed from the seat bottom before operating the vehicle. Failure to do so can result in a fire, property damage, personal injury, or death.

PERFORMANCE INSPECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions, take the vehicle for a test drive. Use the following checklist, in conjunction with the Pre-Operation and Daily Safety Checklist, as a guide to inspect the vehicle and check daily for proper operation. Any problems should be corrected by a Club Car distributor/dealer or a trained technician. • Governor: Check maximum speed of the vehicle. The vehicle should operate at 14 mph (23 km/h) or less on a level surface. With the neutral lockout switch in the MAINTENANCE position, check the maximum engine RPM with a tachometer. The correct setting for safe operation is 2350 RPM (±30). • Forward/Reverse control: Check for proper operation. See Controls and Indicators on page 12. • Brakes: Be sure the brakes function properly. When brake pedal is fully pressed under moderate pressure, it should not go more than halfway to the floor, and vehicle should come to a smooth, straight stop. If the brake pedal goes more than halfway to the floor, or if the vehicle swerves or fails to stop, have the brake system checked and adjusted as required. Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance. • Park brake: When latched, the park brake should lock the wheels and hold the vehicle stationary (on an incline of 20% or less). It should release when either the accelerator or brake pedal is pressed. • Reverse buzzer: The reverse buzzer should sound as a warning when the Forward/Reverse handle or switch is in the REVERSE position. • Steering: The vehicle should be easy to steer and should not have any play in the steering wheel. • General: Listen for any unusual noises such as squeaks or rattles. Check the vehicle ride and performance. Have a Club Car distributor/dealer or a trained technician investigate anything unusual. • Accelerator pedal: With the key switch in the ON position and the Forward/Reverse handle in the FORWARD position, as the accelerator pedal is pressed, the engine should start and the vehicle should accelerate smoothly to full speed. When the pedal is released, it should return to the original position and the engine should stop.

VEHICLE OPERATION

STABILITY To maintain proper stability, the Cafe Express vehicle must not be driven over curbs, or on steep slopes, fairways, or extremely uneven terrain.


Page 19

Vehicle Operation

WARNING • Driving the vehicle over curbs, or on steep slopes, fairways, or extremely uneven terrain can cause vehicle rollover, resulting in serious injury or death.

ENGINE SPEED A Club Car vehicle with a Cafe Express refreshment center installed must have a maximum level ground travel speed of 14 mph (23 km/h) or less. This is controlled by the maximum governed engine RPM. See Performance Inspection.

WARNING • Excessive speed can result in vehicle rollover. Engine RPM must be maintained at the specified setting.

TIRES SPECIFICATIONS

CAFE EXPRESS VEHICLE

Tires

20 x 10 – 10 6-ply 28 to 32 psig

Tire pressure

(193 to 221 kPa)

WARNING • All Cafe Express vehicles must be equipped with 20 x 10 – 10 6-ply rated tires on all four wheels. Never install oversized tires on the vehicle. Oversized tires can increase the vehicle’s maximum travel speed. Oversized tires can also raise the vehicle’s center of gravity, reducing the vehicle stability. • Never install tires that are rated below 6-ply on the vehicle. Less than 6-ply rated tires may not have sufficient side wall strength to adequately support the vehicle. • Correct tire pressure is essential. Low air pressure will reduce vehicle travel speed and result in weakened tire sidewall strength. Tires with weakened sidewall strength will not adequately support the vehicle when making sharp turns. • Tire pressure must be checked daily and adjusted as required on a regular basis.

WINDSHIELD The Cafe Express vehicle is often driven in the opposite direction of play. This exposes the driver to the hazard of flying golf balls.

WARNING • A Club Car vehicle with a Cafe Express refreshment center installed must be equipped with the one-piece windshield supplied with this kit to reduce the hazard of flying golf balls.

Page 20


Driving Instructions

DRIVING INSTRUCTIONS WARNING • Only licensed drivers should be allowed to drive the vehicle. • Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. • No more than two people should be in the vehicle at one time. • Do not allow riders in the cargo bed. • The vehicle is not specially equipped for handicapped persons. Be sure all persons can properly operate the vehicle prior to allowing them to drive the vehicle. • Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one. • For night use, the vehicle must be equipped with headlights, taillights, and reflectors. • Stop the vehicle before shifting the Forward/Reverse handle or switch. Failure to do so can result in injury to inattentive passengers and (or) damage to the vehicle. • Do not leave children unattended in vehicle at any time. • To help avoid being struck, do not stand in front of or behind the vehicle. • Operate the vehicle from the driver seat only. • To help prevent falls from the vehicle, remain seated in a moving vehicle and hold on to hand holds or handrails at all times. Driver should keep both hands on the steering wheel when the vehicle is in motion. • To help prevent the possibility of serious injury, keep entire body inside the vehicle. • To help prevent overturning the vehicle, drive slowly in turns. • Driving the vehicle over curbs, or on steep slopes, fairways, or extremely uneven terrain could cause vehicle rollover, resulting in serious injury or death. • To help prevent overturning the vehicle, drive slowly straight up and down slopes. Avoid driving the vehicle on slopes exceeding 20% incline. • Avoid stopping a loaded vehicle on a hill. If a loaded vehicle must be stopped on a hill, avoid sudden starts or rolling backwards and stopping suddenly. Failure to heed this warning can result in overturning the vehicle. • To help avoid possible injury to inattentive passengers and (or) damage to the vehicle, avoid sudden starts, sudden stops, and abrupt turns. • To help avoid the possibility of losing control of or overturning the vehicle, reduce speed for adverse driving conditions such as wet grass or rough terrain. • Do not use the vehicle on public roads. It is neither designed nor intended for street use and should not be licensed for use on public roads. • The vehicle should be driven in only specified areas by trained drivers. • Do not drive while under the influence of alcohol, drugs, or medications. • Use brakes to reduce speed when coasting downhill. • Do not drive the vehicle under tree limbs, bridges, tunnels, or other objects that are less than 80 inches (203 cm) from the ground. No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle’s controls. An experienced operator should accompany each first-time driver on a test drive before allowing them to operate the vehicle alone. To ensure safe operation of the vehicle, follow exactly and in order, all of the following procedures. Read and understand all instructions prior to driving the vehicle.


Page 21

Driving Instructions

STARTING THE VEHICLE 1.

Read safety and information decals located on the vehicle.

2. 3.

Study and understand controls. Make sure load is secure.

4.

Make sure everyone is seated and holding onto hand holds or handrails. Driver should have both hands on the steering wheel.

5.

Make sure wheels are turned in desired direction and that nothing is obstructing vehicle’s path.

6.

Start the vehicle. 6.1. Turn the key to the ON position. 6.2. Select direction by placing the Forward/Reverse handle or switch in the desired position (F = Forward or R = Reverse). A buzzer will sound as a warning when the Forward/Reverse handle or switch is in the REVERSE position. 6.3. Slowly press the accelerator pedal. The park brake will release automatically and the vehicle will start to move. As the accelerator pedal is pressed, speed will increase until full speed is reached. See following WARNING and NOTE.

WARNING • Operator must control vehicle speed when going downhill. • Stop the vehicle before shifting the Forward/Reverse handle or switch. Failure to do so can result in injury to inattentive passengers and (or) damage to the vehicle. • Press the brake pedal as necessary and partially press the accelerator when descending a hill. With the accelerator pedal partially pressed, the governor will cause the engine to assist the brakes in controlling downhill speed.

STOPPING THE VEHICLE

WARNING • Driving through water can affect the brakes. After driving through water, check effectiveness of the brakes by gently pressing the brake pedal. If the vehicle does not slow down at the normal rate, continue to press the brake pedal until the brakes dry out and normal performance returns. • After stopping the vehicle, firmly set the park brake until it is fully engaged and prevents the vehicle from rolling.

CAUTION • When stopped on a hill, use the brake pedal to hold your position. Do not use the accelerator pedal to hold position. To stop vehicle, release the accelerator pedal and press the brake pedal until vehicle comes to a complete stop.

PARKING AND LEAVING THE VEHICLE 1.

After coming to a complete stop, engage the park brake until it locks the wheels and prevents the vehicle from rolling.

2.

Turn the key switch to the OFF position and place the Forward/Reverse handle or switch in the NEUTRAL position. Remove the key when the vehicle is not in use.

Page 22


Loading and Unloading

LOADING AND UNLOADING WARNING • Engage park brake to lock wheels before loading the vehicle. • Do not allow riders on the refreshment center. • Do not exceed the rated capacity of the vehicle. Rated capacity is for level surfaces only. • Overloading can affect vehicle handling or cause component failure, resulting in loss of control of vehicle and possible serious personal injury. • Reduce vehicle load and speed when driving up or down slopes or on uneven terrain. • Reduce speed and avoid sudden stops when backing up. Failure to do so can cause the vehicle to overturn or flip over backwards. • Avoid stopping on a hill when loaded. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly. Failure to heed this warning can cause vehicle to overturn, possibly resulting in serious personal injury. • To help avoid shifting the vehicle load and possibly overturning the vehicle, avoid sudden starts, sudden stops, and abrupt turns. • The cargo’s center of gravity can affect the handling, steering, and braking of the vehicle. Avoid top-heavy loads. When the vehicle is loaded, reduce speed and drive slowly in turns. • To help prevent cargo from shifting and possibly injuring a passenger or affecting the vehicle’s handling, make sure cargo is well secured. • Unload refreshment center before raising vehicle with a lift, hoist, or jack. • Cargo load includes the weight of optional equipment. When stocking the Cafe Express refreshment center, make sure the load weights are approximately equal in all lower (cold storage) compartments containing ice and/or beverages.

VEHICLE LOAD CAPACITIES Occupant Capacity The occupant capacity is the maximum allowable weight for occupants (operator and passengers) to operate the vehicle safely. Cargo Capacity The cargo capacity is the maximum amount of load that the vehicle can haul in the cargo areas and cargo bed and includes the weight of optional equipment. Vehicle Rated Capacity The vehicle rated capacity is the maximum amount of weight on the vehicle. This capacity includes the weight of occupants, cargo, bed load, and optional equipment. Maximum Gross Vehicle Weight The maximum gross vehicle weight includes the vehicle weight and the vehicle rated capacity. The stated maximum gross vehicle weight must not be exceeded to maintain safe vehicle operation. Refer to Figure 14 for the following specifications.


Page 23

Refreshment Center

Cafe Express A: Occupant Capacity

400 lb (181 kg)

B: Cargo Capacity (includes cargo, bed load and optional equipment.)

450 lb (204.1 kg)

A + B = Vehicle Rated Capacity

850 lb (385.6 kg)

Vehicle Weight

1175 lb (532.9 kg)

A + B + Vehicle Weight = Maximum Gross Vehicle Weight

2025 lb (918.5 kg)

B

A

2925

Figure 14

Vehicle Load Capacity

REFRESHMENT CENTER

REFRESHMENT CENTER COMPARTMENTS Cold Storage Compartments The cold storage compartments are designed to carry canned beverages and cooling ice. Pre-packaged, non-hazardous foods and snacks can also be served from these compartments. We recommend they be kept in plastic containers if placed directly on the ice, so that food will remain dry. Pre-cooling the canned beverages will minimize the amount of ice required to keep the product cool. Maintaining ice in the cold storage compartments when they are not in service will help to maintain a colder temperature when the unit is put back into service.

WARNING • Operate vehicle only with all compartment loads equally distributed. • Do not use the cold storage compartments to store unprotected food, or ice that is intended for human consumption. Failure to heed this warning can result in food poisoning. Consumable Ice Compartments The consumable ice compartments, located in the rear driver and passenger sides of the Cafe Express refreshment center should be used for consumable ice only. In order to prevent contamination of consumable ice, do not place food in these compartments. Consumable ice should not be stored in any other compartment of the Cafe Express refreshment center. Page 24


Towing with the Vehicle Trash Compartment The trash compartment is located in the rear of the base unit. The trash bin should be lined with a disposable plastic bag to maintain cleanliness. This compartment should not be used for storing or transporting consumable ice, drinks, or food.

TOWING WITH THE VEHICLE The Cafe Express vehicle must not be used to tow trailers or other vehicles.

TRANSPORTING ON A TRAILER WARNING • Do not allow riders in the trailer being towed. • Avoid sudden starts, sudden stops, and tight turns when towing. • Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts or rolling backwards and stopping suddenly. Failure to heed this warning can cause the vehicle to overturn, possibly resulting in serious personal injury. • For use on public roads, the trailer must meet all federal, state, and local requirements such as taillights, brake lights, etc. • Reduce normal driving speed when transporting a Club Car vehicle on a trailer. • Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer. • The vehicle to be transported should be tied securely to the trailer, with the Forward/Reverse handle or switch in the NEUTRAL position, the key switch in the OFF position, and the park brake engaged to lock wheels. • Because of the added length of the trailer, use caution when making turns. • Remove the vehicle windshield and canopy and secure the seat bottom before transporting on a trailer. • When trailering the vehicle, make sure the removable front body is correctly installed to prevent separation from the vehicle during transport. • Remove any loose items prior to transporting on a trailer. • Stay clear from the area between the tow vehicle and the towed vehicle or trailer. If the vehicle or vehicles must be transported over long distances or on public highways, they should be transported on an approved trailer that has an approved load rating in excess of the weight of the vehicles being transported.

STORAGE See General Warnings on page 8.


Page 25

Storage

DANGER • Do not attempt to drain fuel when the engine is hot or while it is running. • Be sure to clean up any spilled gasoline before operating the vehicle. • Store fuel in an approved fuel container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources. • Keep fuel out of the reach of children. • Do not siphon fuel from the vehicle.

WARNING • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation. • Turn the key switch to the OFF position, remove the key, and leave the Forward/Reverse handle in the NEUTRAL position during storage. This is to prevent unintentionally starting the vehicle or a fire hazard. • Do not attempt to charge frozen batteries or batteries with bulged cases. Discard the battery. Frozen batteries can explode.

CAUTION • Batteries in a low state of charge will freeze at low temperatures.

PREPARING THE GASOLINE VEHICLE FOR EXTENDED STORAGE 1.

Unload the vehicle so that tires are supporting only the weight of the vehicle.

2.

Store vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at 10 amps or less. Seal the fuel tank.

3.

3.1. Fill fuel tank, and, following manufacturer’s directions, add a commercially available fuel stabilizer (such as Sta-Bil®). 3.2. Disconnect fuel vent line from fuel tank vent nipple. 3.3. Plug the fuel tank vent nipple so that it is air tight. We recommend using a slip-on vinyl cap. NOTE: It is not necessary to drain the fuel line. 4.

Disconnect battery and spark plug wire. See Disconnecting the Battery on page 10.

5.

Batteries should be clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water: use 1 cup (237 mL) baking soda per 1 gallon (3.8 L) of water. Rinse solution off batteries. Do not allow this solution to enter the batteries. Let the terminals dry and then coat them with Battery Terminal Protector Spray.

6.

To protect the engine, remove spark plug and pour 0.5 fl-oz (14.2 mL) of SAE 10 weight oil into the engine through the spark plug hole. Rotate engine crankshaft by hand several times and then install the spark plug and tighten it to 20 ft·lb (27 N·m).

7. 8.

Adjust tires to recommended tire pressure. See Vehicle Specifications on page 39. Perform semiannual periodic lubrication. See Periodic Lubrication Schedule on page 30.

9.

Thoroughly clean front body, rear body, seats, cargo bed, engine compartment, and underside of vehicle.

10. Thoroughly clean and wipe dry all storage compartments in the refreshment center.

Page 26


Storage 11. Do not engage the park brake. Chock the wheels to prevent the vehicle from rolling.

RETURNING THE STORED GASOLINE VEHICLE TO SERVICE 1.

Restore fuel system to operation. 1.1. Remove plug from the fuel tank vent (Figure 21, Page 36). 1.2. Connect vent tube to fuel tank vent.

2.

Connect battery and spark plug wire. See Connecting the Battery on page 10.

3.

Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position. Crank the engine until the engine starts. Turn the engine off and return the neutral lockout switch to the OPERATE position. See following NOTE.

NOTE: Due to the oil added to the engine in preparation for storage, engine may smoke excessively for a short time when it is run for the first time after storage. 4.

Adjust tires to recommended tire pressure. See Vehicle Specifications on page 39.

5.

Perform the Pre-Operation and Daily Safety Checklist on page 18 and the Performance Inspection on page 19.


Page 27

Maintenance

MAINTENANCE See General Warnings on page 8. To ensure trouble-free vehicle performance, it is very important to follow an established preventive maintenance program. Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect. Use the Pre-Operation and Daily Safety Checklist on page 18 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition. Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service.

WARNING • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs can result in fire, property damage, serious personal injury, or death. • Only trained technicians should service or repair the vehicle. Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair. The appropriate instructions must be used when performing maintenance, service, or accessory installation. • Do not work on vehicle powertrain or under the cargo bed when it is loaded. • Do not wear loose clothing or jewelry, such as rings, watches, chains, etc., when servicing the vehicle. • Turn the key switch to OFF, remove the key, place the Forward/Reverse handle or switch in the NEUTRAL position, and chock tires prior to servicing. • Do not close bed until all persons are clear of the bed area. Failure to follow these instructions can result in serious personal injury. • Moving parts: Do not attempt to service gasoline vehicle while the engine is running. • Hot! Do not attempt to service hot engine or exhaust system. Failure to heed this warning can result in serious burns. • To avoid unintentionally starting the vehicle, disconnect battery and spark plug wire. See Disconnecting the Battery on page 10. • Frame ground – Do not allow tools or other metal objects to contact frame when disconnecting batteries or other electrical wiring. Never allow a positive wire to touch the vehicle frame, engine, or other metal component.

PERIODIC SERVICE SCHEDULE See General Warnings on page 8.

WARNING • Service, repairs, and adjustments must be made per instructions in the maintenance and service manual. • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs can result in fire, property damage, serious personal injury, or death. NOTE: If the vehicle is constantly hauling heavy loads or hauling a trailer, these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule. Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition.

Page 28


Periodic Service Schedule

PERIODIC SERVICE SCHEDULE REGULAR INTERVAL

SERVICE Pre-Operation and Daily Safety Checklist

Daily service by owner

Performance Inspection

See Pre-Operation and Daily Safety Checklist on page 18. See Performance Inspection on page 19. Check air pressure and adjust if necessary.

Tires

See Vehicle Specifications on page 39. Check engine oil level; change if necessary. See Periodic Lubrication Schedule on page 30. Dispose of used oil properly.

Engine

Check engine cooling air intake; visually inspect unshrouded area around engine

Monthly service by owner or trained

exhaust for grass and debris, and clean if

technician

necessary. Wash engine compartment and underside of

General vehicle

vehicle. Do not wash engine when hot.

Door locks

Lubricate with a dry lubricant. Clean terminals and wash dirt from casing;

Battery

check electrolyte level (Figure 16). Check and adjust if necessary.

Front wheel alignment and camber

See Steering and Front Suspension section in the maintenance and service manual.

Semiannual service by trained technician

Electrical wiring and connections

only (or every 50 hours of operation, whichever comes first)

Check for tightness and damage. Check brake shoes; replace if necessary or adjust as required.

Brake system

Check brake cables for damage; replace as required. Check brake cable equalizer adjustment; adjust if necessary. Check for leaks around gaskets, fill plugs, etc.

Engine

Inspect, clean and gap spark plug; replace if necessary. Check air filter element; clean or replace if

Annual service by trained technician only (or every 100 hours of operation, whichever comes first)

necessary. Engine air intake system Check clamps for tightness; check hose for cracks. General vehicle

Safety decals Two-year service by trained technician only.

Engine

Check for loose hardware and tighten if necessary. Check safety decals. Replace if damaged or illegible. Check and adjust valve lash as needed.


Page 29

Periodic Lubrication Schedule

PERIODIC LUBRICATION SCHEDULE

PERIODIC LUBRICATION SCHEDULE REGULAR INTERVAL

LUBRICATION

SERVICE

Semiannually by owner or

Brake pedal shaft bearings

1

Dry Moly Lube (CC PN 1012151)

Brake linkage and pivots

2


trained technician (or every 50

Accelerator pivot rod supports and

hours of operation, whichever

shifter cable pivots

comes first)

Annually by trained technician

RECOMMENDED LUBRICANT

POINTS


Front suspension

Chassis Lube (EP NLGI Grade 2)

Brake slides


Transaxle: Check/fill to plug level

67.6 fl-oz (2 L) SAE 80W-90 API Class GL-5

only (or every 100 hours of operation, whichever comes

Inspect front wheel bearings (Repack

first)

as necessary)

7

Chassis Lube – EP NLGI Grade 2

First change 100 hours – additional change every 200 hours of operation or annually,

40.5 fl-oz (1.2 L) 10W-30 or

8

Change engine oil

5W-30 grade SE or higher See also Figure 20, Page 35.

whichever comes first

7 2

5

3

5 3

1

3

4

2

3 1

6

8

4

5

5

7

2823

Figure 15

Page 30

Lubrication Points


Battery

BATTERY See General Warnings on page 8.

DANGER • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. • Tools, wires, and metal objects can cause sparks when shorted across a battery. • Follow all instructions carefully when working with batteries. • Charge battery in a well-ventilated area only. • Battery – Poison! Contains acid! Causes serious burns. Avoid contact with skin, eyes, or clothing. Antidotes: – External: Flush with water. Call a physician immediately. – Internal: Drink large quantities of milk or water followed with milk of magnesia or vegetable oil. Call a physician immediately. – Eyes: Flush with water for 15 minutes. Call a physician immediately.

WARNING • Do not jump-start a dead battery using another battery and jumper cables. The battery in a Club Car gasoline vehicle is a 12-volt, low-maintenance battery that requires infrequent watering (Figure 16).

2 1

3

1. Level Indicator 2. Cap 3. Plates Electrolyte level at least 1/2 inch (13 mm) above plates or to level indicator.

2831

22

Figure 16 Gasoline Vehicle Battery

Figure 17 Electrolyte Level for Battery

Any corrosion around the positive (+) or negative (–) terminals should be washed off with a solution of baking soda and water (1 cup (237 mL) per 1 gallon (3.8 L) of water). Rinse solution off the battery. Do not allow this solution to get into CAFE EXPRESS Vehicle Owner’s Manual

Page 31

Engine Oil – Gasoline Vehicle the battery. Be sure terminals are tight. Let the terminals dry and then spray them with Battery Terminal Protector Spray. See Connecting the Battery on page 10. See following WARNING.

WARNING • If battery wire terminals are damaged or corroded, replace or clean them as necessary. Failure to do so can cause them to overheat during operation and can result in a fire, property damage, or personal injury. Be sure battery clamp is properly tightened. Tighten to 144 in·Ib (16 N·m). A loose clamp may allow the battery to become damaged from vibration or jarring. If battery appears weak, have it charged by a trained technician. The battery should never be left discharged any longer than absolutely necessary (do not leave discharged overnight).

ENGINE OIL – GASOLINE VEHICLE Even though the low oil warning light on the dash should illuminate if oil level becomes low, engine oil level should be checked monthly. Vehicle should be on a level surface when checking oil. Do not overfill with oil.

ENGINE OIL LEVEL CHECK 1.

Remove the oil level dipstick from the oil filler tube, and wipe oil off dipstick (Figure 18). See following CAUTION.

CAUTION • Do not remove dipstick while engine is running. 2.

Check oil by fully inserting the dipstick into the oil filler tube and immediately removing it.

3.

If the oil level is at or below the low level mark on the dipstick gauge, add oil until the level is between low and full levels (safe level).

4.

Insert the dipstick into the oil filler tube. See following NOTE.

NOTE: Properly recycle or dispose of used oil in accordance with local, state, and federal regulations.

Page 32


Engine Oil – Gasoline Vehicle

1

2

3

1. Full level 2. Safe level 3. Low level 2662

Figure 18 Engine Oil Level Check

ENGINE OIL CHANGE Engine oil should be changed after the first 100 hours of operation. After that, it should be changed every 200 hours of operation or annually, whichever comes first. 1.

Turn the key switch to the OFF position, then remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels.

2.

Access the engine compartment.

3.

Disconnect battery and spark plug wire. See Disconnecting the Battery on page 10.

4.

Position a pan designed for oil changes under the drain plug (1) (Figure 19).


Page 33

Engine Oil – Gasoline Vehicle

2

1 1. Drain pan 2. Drain plug

2667

Figure 19

5.

Engine Oil Drain Plug and Pan

Use a 14 mm socket or wrench to remove the drain plug, turning it counterclockwise, and allow the engine oil to drain into the pan. See following WARNING.

WARNING • Do not attempt to change engine oil when the engine is hot or even warm. Engine oil can cause skin burns. • Wear safety glasses or approved eye protection when servicing the vehicle. Wear rubber gloves when handling oil drain plug and oil drain pan. 6.

Clean the oil drain plug threads with solvent to remove oil and oil residue. Make sure that the compression washer remains on the drain plug.

7.

Use a 14 mm socket or wrench and replace the oil drain plug, turning it clockwise, and tighten to 18 ft·lb (24.4 N·m).

8.

Remove the dipstick and add engine oil into the dipstick port. Use a funnel or pour spout to direct the oil into the dipstick port. The engine requires 40.5 fl-oz (1.2 L) of oil per change. 10W-30 or 5W-30 grade SE or higher is recommended. Refer to oil viscosity guidelines for selection of oil grade (Figure 20). Replace the dipstick.

Page 34


Fueling Instructions – Gasoline Vehicle

SAE 40

SAE 30 SAE 10W-30/ SAE 10W-40 SAE 5 W-30

213

Figure 20 Oil Viscosity Chart

9.

Connect battery and spark plug wire. See Connecting the Battery on page 10.

10. With the Forward/Reverse handle in the NEUTRAL position and the Maintenance/Service switch in the SERVICE position, start and run the engine for a few minutes. Observe the drain plug from under the vehicle and watch for oil leaks. If leaks appear, begin with step 1 and repeat the appropriate steps as needed to correct the problem. 11.

Remove the dip stick and check the engine oil as a final step. Replace the dip stick.

FUELING INSTRUCTIONS – GASOLINE VEHICLE See General Warnings on page 8.

DANGER • Turn the key switch to the OFF position before fueling. • Do not pour fuel into the fuel tank when the engine is hot or while it is running. • Be sure the fuel tank ground wire on the tank is properly connected before fueling the vehicle. • To avoid electric arc caused by static electricity, the fuel storage/pumping device must be grounded. If the pump is not grounded, the vehicle must be grounded to the pump before and during the fueling operation. • If the vehicle has an all-weather enclosure installed, be sure the fuel tank is properly vented as shown in Figure 21. • To avoid the possibility of fire, clean up any spilled fuel before operating the vehicle.

CAUTION • Use unleaded gasoline only. • Whenever possible, avoid using oxygenated and blended fuels. • Do not use any fuel with an alcohol content that exceeds 10% by volume (such as E15 and E85). Ethanol is an alcohol that readily absorbs moisture, causing corrosion of fuel system components. It also damages neoprene and other plastic and rubber components. Use of these fuels in this vehicle will void the warranty. • Do not repeatedly attempt to start a vehicle when the fuel pump is dry (no gas in tank). Doing so can damage the fuel pump. CAFE EXPRESS Vehicle Owner’s Manual

Page 35

Cleaning the Vehicle NOTE: Whenever possible, avoid using oxygenated fuels and fuels that are blended with alcohol. Vehicles to be stored for extended periods should be prepared for storage as instructed. See Preparing the Gasoline Vehicle for Extended Storage on page 26. 1.

Remove the fuel cap located on the passenger-side panel and fill the fuel tank with fresh unleaded gasoline only. See preceding CAUTION and NOTE.

2.

Replace fuel cap on tank. Ensure cap is tightened securely (tighten until it clicks).

1

2

3 1. Vent 2. Fuel Vent Line 3. Fuel Tank

2832

Figure 21 Fuel Tank

CLEANING THE VEHICLE

VEHICLE CHASSIS The vehicle is equipped with an ArmorFlex® front body and an all-aluminum rear body. Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate. To remove oxidation or discoloration from aluminum, use a commercially available aluminum cleaner paste and fine grade (No. 00) steel wool. Club Car does not recommend any type of pressure washer or steam cleaning. Such a process will expose electrical components to moisture. Moisture entering electrical components can result in water damage and subsequent component failure. Use non-abrasive wax products. Battery acid, fertilizers, tars, asphalt, creosote, paint, or chewing gum should be removed immediately to prevent possible stains. The seats of the vehicle will last longer with proper cleaning. Use a solution of 10% liquid soap and warm water applied with a soft cloth. For imbedded dirt, a soft bristle brush may be used. For heavy soiling, difficult stains or scratches, blemishes, or other body damage, see the Maintenance and Service Manual or contact your local Club Car dealer. NOTE: Dispose of waste water properly.

Page 36


Accessories

WINDSHIELD Use only mild liquid dishwasher soap with a sponge or soft cloth for cleaning the windshield.

CAUTION • Do not use glass-cleaning products on the windshield.

REFRESHMENT CENTER Interior Aluminum Surfaces The interior surfaces of the refreshment center should be cleaned and sanitized daily with an approved product before being used. Check with your local Health Department for rules and regulations in your area. Exterior Aluminum Surfaces The exterior surfaces should be cleaned on a daily basis using a soap and water solution. Periodic cleaning with an aluminum or stainless steel cleaner is recommended.

CAUTION • Using abrasive cleaners on aluminum will damage or scratch the surface. Use a soft cloth with an industrial type aluminum cleaner/polish to clean the aluminum surfaces. • Do not use steel wool on refreshment center aluminum surfaces. Drains The drains should be flushed with a hose on a daily basis. Periodically, the drains should be cleaned and sanitized. Refreshment Center Doors The sliding doors should be cleaned daily with a mild soap and water solution. Dry with a clean, damp chamois. Do not use window cleaning sprays or paper towels. Canopy Cover Periodically clean the canopy cover by spraying the fabric with water and allowing fabric to dry on the canopy frame.

ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers/distributors. You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www.clubcar.com and clicking the “Dealer Locator” link. Care should be taken that these accessories are properly installed by trained technicians, and they are used in the manner for which they were designed. See following WARNING.

WARNING • Custom cab assemblies, weatherproof enclosures, door kits, and tinted windshields will not protect occupants from flying objects. • If the vehicle is equipped with an electric powered lift bed, remove the bed before servicing the bed lift system. • Cargo load includes the weight of optional equipment. See Vehicle Load Capacities on page 23.


Page 37

Subsequent Owner Registration

CAUTION • Combined use of electric-powered accessories for an extended period of time can discharge the battery even with the engine running. Be aware of charging system capacity rating and keep combined accessory use at or below that rating. See Vehicle Specifications on page 39. Failure to heed this caution can result in the vehicle shutting off, possibly leaving operator and passenger stranded.

SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle, we strongly urge the new owner to register the vehicle with Club Car. This will enable us to contact you if the need arises. Please send your name, address, and serial number(s) of the vehicle(s) to Club Car, LLC, P.O. Box 204658, Augusta, Georgia 30917-4658, Attention: Vehicle Registration.

Page 38


Vehicle Specifications

VEHICLE SPECIFICATIONS NOTE: Engine horsepower and torque specifications are provided by the engine manufacturer. Actual horsepower and torque in use may differ and are dependent on environmental conditions as well as maintenance condition of the engine. SPECIFICATIONS

CAFE EXPRESS

POWER SOURCE

GASOLINE

Engine: 4 cycle, OHC, 404 cc, 14.0 Horsepower (10.4 kW) rated engine @ 3600 RPM (per SAE J 1940), single cylinder, air cooled, with splash lubrication system

●

Fuel system: Electronic fuel injection (EFI), high-pressure rotary fuel pump with 10 micron fuel filter

●

Governor: Automatic ground speed sensing, internally geared in transaxle

●

Ignition: Digital CDI with electronic RPM limiter

●

Transaxle: Precision helical gears, forward/reverse with neutral position (11.47:1 forward; 15.63:1 reverse), with optional limited slip differential Electrical system: 12 volt, 500 cca at 0 °F (-17.8 °C), 650 cca at 32 °F (0 °C). 105-minute reserve capacity

● ●

Gasoline Vehicle Electrical Charging System: ● 23 amps at max. RPM. Torque converter: Automatic, variable speed, dry type

●

STEERING/SUSPENSION/BRAKES Steering: Self-adjusting rack and pinion

●

Suspension: Independent leaf spring with dual hydraulic shocks

●

Brakes: Mechanical brake cable system to manually-adjusted drum brakes on all four wheels. Park brake is automatically released. Multi-latch ratchet and pawl.

●

BODY/CHASSIS Frame/chassis: Twin I-Beam welded aluminum

●

Side and rear body: Aluminum

●

Front body: ArmorFlex®

●

Front body finish: Automotive-grade paint with clear-coat finish

●

Tires: 20 x 10 - 10 tubeless, 6-ply rated load range front and rear

●

DIMENSIONS/WEIGHT Overall length: Standard configuration 125.5 in (318.7 cm) Add for Heavy-Duty Bumper: 1.8 in (4.5 cm) Overall width

51.4 in (130.5 cm)

with mirrors:

62.6 in (159.0 cm)

Overall height: at steering wheel

47.1 in (119.6 cm)

Overall height: with canopy

70.7 in (179.5 cm)

Wheelbase

78.1 in (198.3 cm)

Ground clearance

5.2 in (13.2 cm)

Front wheel tread

36.6 in (92.9 cm)

Rear wheel tread

39.5 in (100.3 cm)


Page 39

Vehicle Specifications

SPECIFICATIONS

CAFE EXPRESS

POWER SOURCE

GASOLINE

Weight: Standard gasoline vehicle with Cafe Express unit (dry fuel tank)

1147 lb (520.2 kg)

Curb weight:

1175 lb (532.9 kg)

Maximum forward speed Outside clearance circle (diameter)

12 to 14 mph (19 to 23 km/h) 258.5 in (656.5 cm)

Turning radius (per SAE J 695)

123 in (312.4 cm)

Intersecting aisle clearance

94 in (238.7 cm)

Floorboard height

7.2 in (18.2 cm)

Load bed size: Cafe Express unit dimensions Vehicle rated capacity: Level surface only Standard seating capacity: (persons)

56.7 x 50.5 x 41.5 in (144 x 128.2 x 105.4 cm) 850 lb (385.6 kg) 2

LIQUID CAPACITIES Engine crankcase

40.5 fl-oz (1.2 L)

Transaxle

67.6 fl-oz (2 L)

Fuel tank

4.6 gallons (17.4 L)

TIRE PRESSURE 28 to 32 psig Front and rear (193 to 221 kPa) NOISE AND VIBRATION Drive-by noise level to operator

77.2 dBa

Test method: EN 12053:2001

Uncertainty: 2 dBa

Vibration at driver’s seat

Unknown at time of printing.

Test method: EN 13059:2002

Uncertainty: 0.23 m/s2

Page 40


Warranties

WARRANTIES

CLUB CAR® LIMITED WARRANTY FOR TRANSPORTATION AND UTILITY VEHICLES WARRANTY CLUB CAR, LLC (“CLUB CAR”) hereby warrants to the Original Purchaser or Lessee, as those terms are defined herein, and subject to the provisions, limitations and exclusions in this limited warranty, that its new vehicle or new component purchased from CLUB CAR or an Authorized Dealer or Distributor shall be free from defects in material and workmanship under normal use and service for the periods stated below, subject to the provisions, limitations and exclusions in this limited warranty. This limited warranty covers material, workmanship and repair labor cost as to those items specifically listed below for the periods specified. Such repair labor shall be performed only by CLUB CAR, its Authorized Dealers or Distributors, or a service agency approved by CLUB CAR. For repairs made by qualified technicians other than CLUB CAR’s factory technicians or an Authorized Dealer or Distributor, CLUB CAR will provide only the replacement parts or components. IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE, PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM. TERMS

TO THE ORIGINAL OWNER ONLY (NON-TRANSFERABLE)

COVERED

LIMITED THREE YEAR: Engine assembly, transaxle assembly (gasoline vehicle), starter/generator (gasoline

HOURS/ AMP HOURS COVERED

3 YEARS

3000

2 YEARS

2000

6-VOLT BATTERY (STANDARD DUTY)

4 YEARS

18000

6-VOLT BATTERY (HEAVY DUTY)

4 YEARS

20000

8-VOLT BATTERY (STANDARD/HEAVY DUTY)

4 YEARS

16000

ONBOARD COMPUTER (IF SO EQUIPPED)

4 YEARS

16000

CONTROLLER

4 YEARS

16000

vehicle), motor, transaxle assembly (electric vehicle), and main frame assembly. LIMITED TWO YEAR: Solenoid, MCOR, limit switches, voltage regulators, FNR switches, brake components, wiring harness, electrical switches, canopy systems, seats, pedal group assembly, body, cab assembly and doors, and driving range protective enclosure, portable refreshment center and all original equipment options and accessories supplied by CLUB CAR, and all remaining components of the vehicle not specified otherwise.

BATTERY CHARGER

4 YEARS

EXCLUSIONS Excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including poor maintenance, neglect, abuse, accident and collision, maintenance adjustments, unreasonable or unintended strain or use, improper installation of accessories, installation of parts or accessories that are not original equipment including Club Car approved or non-approved GPS systems, non-approved alteration and acts of God. Also excluded from any CLUB CAR warranty are all fuses, filters, decals (except safety decals), lubricants, routine wear items such as the charger plug and receptacle, engine mounts, bed floor lining, mats, pads, spark plugs, light bulbs, brake shoes, belts, brushes, bushings, drive buttons, cosmetic deterioration, and items that deteriorate, fade or fail due to exposure or ordinary wear and tear. The provisions of this limited warranty shall not apply to failure due to the following conditions: 1.

Abuse such as overcharging, undercharging, improper fluid levels, loose wiring and fasteners, or rusted or corroded hardware.

2.

Use of water in batteries, including tap water, that contains impurities. Distilled water or a properly maintained, Club Car approved battery water deionizer and filter system should be used to ensure water quality. CAFE EXPRESS Vehicle Owner’s Manual

Page 41

Warranties 3.

Lack of proper maintenance such as preventive maintenance checks, proper rotation of vehicles in a fleet application, maintaining proper tire pressure and alignment and tightening loose wire connections as outlined in the owner’s manual.

4.

Damages caused by improper installation of the component.

5.

Neglect, breakage, freezing, fire, explosion, wreckage, melted terminal posts, the addition of any chemical, or the operation of the battery in an uncharged condition (below half charge 1.200 specific gravity); the installation of the batteries in reverse or recharging in reverse, breakage of containers, covers, or terminal post, or batteries used in applications for which they were not designed.

6.

A battery damaged by a defective charger or batteries in vehicles that do not receive proper charging.

7.

A vehicle not having an operational charger on a circuit that has the parameters specified in the vehicle owner’s manual. (Number of operational chargers must equal the number of operational vehicles.) Improper charging of a vehicle due to the use of a battery charger model not approved by Club Car for use with the vehicle.

8. 9.

Failed semiconductor parts such diodes and fuses that are vulnerable to electrical overloads (including lightning) beyond the control of CLUB CAR.

10. Damaged charger DC cord set with plug, which is a wear item and subject to user abuse. 11. Use of gasoline containing more than 10% ethanol. Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, CLUB CAR does not warrant that its vehicle or components such as batteries, computer, controller or electrical device are suitable for use in any application other than in its products. As in the use of any vehicle, batteries, computer, controller or electrical device, a prudent owner will read and study the owner’s manual, the operator instructions and the warning labels; and will exercise due care in working on or around vehicles, batteries or electrical devices. Transportation expenses for warranty services are also excluded from this warranty. VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE OR COMPONENT IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY, INCLUDING, BUT NOT LIMITED TO, MODIFICATION OF THE SPEED GOVERNOR, BRAKING SYSTEM, STEERING, TRANSAXLE, OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS. THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER’S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS. SOLE REMEDY CLUB CAR’s liability under this limited warranty or in any action whether based upon warranty, contract, negligence, strict product liability or otherwise, shall be the repair or replacement, at CLUB CAR’s option, of the vehicle or component thereof that CLUB CAR deems to be defective. Replacement shall mean furnishing, during the applicable limited warranty period, a new vehicle or factory-reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component at no cost to the purchaser. Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period. CLUB CAR reserves the right to test and recharge any component returned for adjustment. If CLUB CAR elects to repair the vehicle or component, it may provide factory-reconditioned parts or components. All parts and components replaced under warranty shall become the property of CLUB CAR. DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE. CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY. THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER. CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT, WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY.

Page 42


Warranties In the event that another pre-printed warranty document, certificate or both offered by or through Club Car at the time of sale of this vehicle (each an “Additional Warranty Document”) is deemed to conflict with the limitations or exclusions contained herein, the limitations and exclusions contained herein shall continue to apply to both this limited warranty statement and, to the maximum extent permitted by law, to each Additional Warranty Document. NO CONSEQUENTIAL DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE, LOSS OF USE, LOSS OF TIME, INCONVENIENCE, OR ANY OTHER ECONOMIC LOSS. Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state. HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warranty, you must present the vehicle or defective component with evidence of proof of purchase date and number of amp-hours (if applicable) to an authorized CLUB CAR dealer. For warranty-related communication, contact Warranty Services, Club Car, 4125 Washington Rd., Evans, GA 30809, USA, 706.863.3000. WARNING Any modification or change to the vehicle that affects the electrical system, stability or handling of the vehicle, or increases maximum vehicle speed beyond factory specifications, can result in serious personal injury or death.

FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California. Club Car, LLC (“CLUB CAR”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (“engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period. For the components listed under PARTS COVERED, the service dealer authorized by CLUB CAR will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations. EMISSION COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of three years. PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. EXHAUST EMISSIONS 1.

Fuel Metering System 1.1. Carburetor and internal parts (and/or pressure regulator or fuel injection system) 1.2. Air/fuel ratio feedback and control system, if applicable

2.

1.3. Cold start enrichment system, if applicable Air Induction System 2.1. Intake manifold, if applicable


Page 43

Warranties 2.2. Air filter 3.

Ignition System 3.1. Spark plugs 3.2. Magneto or electronic ignition system 3.3. Spark advance/retard system, if applicable

4.

Catalyst or Thermal Reactor System 4.1. Exhaust Manifold, if applicable

5.

Miscellaneous Items Used in Above Systems 5.1. Electronic controls, if applicable 5.2. Hoses, belts, connectors, and assemblies

EVAPORATIVE EMISSIONS 1.

Fuel Line

2.

Fuel Line Fittings

3.

Clamps

4. 5.

Fuel Tank Fuel Cap

6.

Vapor Hoses

7.

Carbon Canister

8. 9.

Carbon Canister Mounting Brackets Air Cleaner Purge Port Connector

REPLACEMENT PARTS DISTRIBUTION CENTER Replacement parts are provided to the market upon request by the customers. Replacement parts distribution center is located at the Service Parts Department, Club Car, 4125 Washington Road, Evans, Georgia 30809, U.S.A., 706-863-3000. If you have a question regarding your replacement part, you should contact CLUB CAR at 706-863-3000. OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized CLUB CAR service dealer. Bring your sales receipts indicating date of purchase for this engine. The service dealer authorized by CLUB CAR will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of CLUB CAR. For owners located more than 100 miles from an authorized service center, the following will be provided to those applicable owners (excluding the states with high-altitude areas). • CLUB CAR will either pay for the shipping costs of replacement parts to and from an authorized service center. • Or CLUB CAR will provide for a service technician to come to the owner to make the warranty repair. • Or CLUB CAR will pay for the repair to be made at a local non-authorized service center. WHAT IS NOT COVERED • Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by CLUB CAR during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required maintenance services. • The replacement parts used for required maintenance services. • Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. Page 44


Warranties • Diagnosis and inspection charges that do not result in warranty-eligible service being performed. • Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts. OWNER’S WARRANTY RESPONSIBILITIES As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. CLUB CAR recommends that you retain all receipts covering maintenance on your engine, but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the engine owner, you should however be aware that CLUB CAR may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest service dealer authorized by CLUB CAR when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the CLUB CAR customer service department at 706-863-3000 for the information. THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. CLUB CAR reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records. MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY CLUB CAR. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM. If other than the parts authorized by CLUB CAR are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by CLUB CAR in their performance and durability. HOW TO MAKE A CLAIM All repairs qualifying under this limited warranty must be performed by a service dealer authorized by CLUB CAR. In the event that any emission-related part is found to be defective during the warranty period, you shall notify CLUB CAR customer service department at 706-863-3000 and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed.

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board (“CARB”) and Club Car, LLC (“CLUB CAR”) are pleased to explain the emission control system warranty on your 2014 or newer vehicle engine (the “emission warranty”). In California, new small off-road engines (“SORE”) must be designed, built and equipped to meet the State’s stringent anti-smog standards. CLUB CAR shall warrant the emission control system on the vehicle engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your small off-road engine.


Page 45

Warranties Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, the catalytic converter and related hoses, belts, connectors and other emission assemblies or components. Where a warrantable condition exists, as defined herein, CLUB CAR will repair your vehicle engine at no cost to you including diagnosis, parts and labor. MANUFACTURER’S WARRANTY COVERAGE: This emission control system is warranted for two years from the vehicles’ date of purchase. If any emission-related part on your CLUB CAR SORE is defective, the part will be repaired or replaced by CLUB CAR. OWNER’S WARRANTY RESPONSIBILITIES: - As the vehicle engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. CLUB CAR recommends that you retain all receipts covering maintenance on your vehicle engine, but CLUB CAR cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. - As the vehicle engine owner, you should however be aware that CLUB CAR may deny you warranty coverage if vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. - You are responsible for presenting vehicle engine to a CLUB CAR distribution center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact WARRANTY SERVICES, CLUB CAR, LLC, P.O. Box 204658, Augusta, Georgia 30917-4658, U.S.A., 1-706-863-3000. CLUB CAR EXPLANATION OF EMISSION CONTROL WARRANTY: 1. WARRANTY: CLUB CAR warrants to the ultimate purchaser and each subsequent purchaser that the SORE and related emissions equipment is designed, built and equipped so as to conform with all applicable California environmental emission regulations; and free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in CLUB CAR’s application for certification with CARB. The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service. The warranty period is two years from the date of purchase. 2. COVERAGE: Subject to certain conditions and exclusions as stated below, the warranty on emission-related parts is as follows: (1) Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied, is warranted for the warranty period stated above. If the part fails during the period of warranty coverage, the part will be repaired or replaced by CLUB CAR according to subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty period. (2) Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period. (3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement, the part will be repaired or replaced by CLUB CAR according to subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part. (4) Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station* at no charge to the owner. (5) Notwithstanding the provisions herein, warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment. (6) The engine or equipment owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at a warranty station*. (7) CLUB CAR is liable for damages to other engine or equipment components proximately caused by a covered failure under warranty of any warranted part. (8) Throughout the engine or equipment warranty period stated above, CLUB CAR will maintain a supply of warranted parts sufficient to meet the expected demand for such parts. (9) Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use will not reduce the warranty obligations of CLUB CAR.

Page 46


Warranties (10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims. CLUB CAR will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part. *CLUB CAR, its authorized dealers, or a service agency approved by CLUB CAR. ITEMS COVERED BY THIS WARRANTY: The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if CLUB CAR demonstrates that the engine or equipment has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part. That notwithstanding, any adjustment of a component that has a factory installed, and properly operating, adjustment limiting device is still eligible for warranty coverage. The following emission warranty parts list are covered: SYSTEMS COVERED PARTS DESCRIPTION Fuel Metering Carburetor assembly, fuel injection pump, fuel injection nozzle, fuel regulator Exhaust Catalytic Converter, Exhaust Manifold Air Induction Air filter housing, air filter*, crankcase breather tube Ignition Flywheel magneto, ignition pulse generator, ignition coil assembly, ignition control module, spark plug cap, spark plug* Positive Crankcase Ventilation (PCV) System PCV valve, oil filler cap Evaporative System Fuel Tank, Fuel Cap, Fuel Lines, Fuel Line Fittings, Clamps, Pressure Relief Valves, Purge Valves, Vapor Hoses, Carbon Canister, Canister Mounting Brackets, Carbon Canister Purge Port Connector Misc. Parts Belts, hosing, tubing, fittings, seals, gaskets, clamps, and switches associated with the above systems. Emission-related parts will vary between vehicles; therefore, certain vehicles may not include all of the listed parts or may include equivalent parts. 3. VOIDING OF WARRANTY: THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY, INCLUDING, BUT NOT LIMITED TO, MODIFICATION OF THE SPEED GOVERNOR, BRAKING SYSTEM, STEERING, TRANSAXLE, OR OTHER OPERATING SYSTEMS OF THE VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS. 4. HOW TO MAKE A WARRANTY CLAIM: To make a warranty claim under this limited warranty, you must present the vehicle or defective component to an authorized CLUB CAR dealer.


Page 47

EC Declaration of Conformity

EC DECLARATION OF CONFORMITY When properly configured, the vehicle complies with the listed Directives.

De c la ra tion o f Co n fo rm ity Mode l Code MD

Mode l Numbe r 104030601

Mode l Na me Ca fé Expre s s

S e ria l numbe rs 1401000001 a nd gre a te r Four-whe e l ve hicle s in the a bove s e rie s tha t be a r the CE ma rk fulfill a ll the re le va nt provis ions of the following Dire ctive s Ens pricht de n Bes timmunge n, Conforme Aux Dire ctive s , Conforme Con La s Directiva s , Voldoe t a a n Richtlijne n, De Acordo com Dire ctiva , Conforme Alla Dire ttiva , Opfylde r folge nde direktive r, Upptylle r folja nde direktiv

2006/42/EC 2006/66/EC

Ma chine ry Ba tte rie s a nd Accumula tors a nd Wa s te Ba tte rie s a nd Accumula tors

S ta nda rds us e d for ve rifica tion S ta nda rds fur Ube rprufung, Norme s Utilis e e s pour Ve rification, Normas Us a do por Comproba cion, Wa a rde n Aa nge we nd voor Ve rifica tie, Mode los Utiliza do pa ra Ve rifcaca o, S ta nda rd pe r la Ve rifica , S ta nda rde r Anve ndte Nemlig Efte rprovning, S ta nda rden Anva nd for Be kra fta nde n

N/A Ma nufa cture r He rs te lle r, Fa brica nt, Fa brica nte , Fa brika nt, Fa brica nte, Fa bbrica nte, P roduce nt, Tillve rka re

Club Ca r, LLC 4125 Wa s hington Roa d Eva ns , Ge orgia 30809 US A Authorize d re pre s e nta tive a nd pe rs on a uthorize d to compile the te chnica l file Autoris ie rte r Hä ndle r, Re pre s e ntant Dume nt Accré dité , Re pre s e nta nte Autoriza do, Wettige Ve rte ge nwoordiging, Re pre s e nta te Autoriza do, Ra ppre s e nta nte Autorizza to, Autoris cre t re præ s e nta nt, Auktoris e ra d re pre s e nta nt:

Club Ca r Inge rs oll Ra nd Alma Court Building Le nne ke Ma re la a n 6 B-1932 S int-S te ve ns -Woluwe , Be lgium

_______________________________________________ Ge off S te wa rt S e pte mbe r 17, 2013 Dire ctor, P roduct S a fe ty Eva ns , Ge orgia , US A

Page 48


NOTES

NOTES

NOTES

NOTES

BC56671

Publication Part Number 105062712 Edition Code 1113B0114A This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page.

105062712